Gas can storage best practices

Why gas can storage matters

Gasoline is a Class 1 flammable liquid with a low flash point, and its vapors are heavier than air. That means vapors can drift and pool along the floor or in crevices where an ignition source might be present. Good gas can storage prevents vapor buildup, reduces fire risk, and protects people, property, and the vehicle. The right container, the right location, and the right restraint system work together to manage risk whether you are at home or on the highway.

Approved containers and identification

Only store fuel in containers that are listed or certified for flammable liquids. Look for markings that indicate compliance with standards such as UL, ASTM, or UN and DOT for transport. Steel and HDPE are both common, but wall thickness, cap design, and spout quality matter. Modern spouts must control evaporation and spills, and local rules may require a specific spill control design.

Color and labeling help avoid mixups. Red is widely used for gasoline, yellow for diesel, and blue for kerosene. Add a clear label with the fuel type and the date you filled the can. Leave expansion space in the container because fuel expands with heat. Avoid overfilling, and keep caps fully seated to contain vapors. Never modify a container or use an unapproved vessel like a water jug.

Static, filling, and ventilation

When filling a portable can, place it on the ground so static charge can dissipate, and keep the nozzle in contact with the can while fueling. Do not fill inside a vehicle or in a closed space. After filling, wipe drips, snug the cap, and vent the area before transporting. Ventilation is essential for storage. A detached shed or well vented outbuilding is usually safer than an attached garage. Never store fuel in a living space or near ignition sources like water heaters, inverters, or battery chargers.

Quantity limits and code awareness

Many jurisdictions limit how much gasoline you can store at a residence. A common cap is twenty five gallons, but always check your local fire code. Keep containers off the floor on a stable surface, upright, and protected from direct sun. Use a metal safety cabinet for larger quantities to add fire protection and organized containment. Secondary containment trays or spill decks catch drips and make cleanup easier.

Vehicle transport and overland use

Carrying fuel on the road adds motion, heat, and crash forces to the safety equation. Inside a cabin, even small vapor leaks can concentrate. The safest approach is outside the interior volume in a lockable carrier. Rear swing out systems and bumper mounted brackets keep cans upright and ventilated. Roof racks are possible, but they raise the center of gravity and make refueling cumbersome. If you must carry fuel inside a van, use certified containers inside a ventilated, sealed compartment with a vapor barrier and drain. Keep fuel away from inverters, heaters, and battery banks.

Securement is a must. Use purpose built jerry can mounts with locking straps or clamps. Test for movement by rocking the can and the mount. Straps should be rated for the load and should not abrade against sharp edges. Keep exhaust heat in mind and route mounts out of the hot plume. Plan for weight distribution. Two full metal jerry cans can add significant mass behind the axle, which affects handling and braking.

Heat, altitude, and expansion

As elevation increases, pressure drops, and cans may vent vapor more readily. Temperature swings cause expansion and contraction, so leave expansion space and check caps during long climbs. In desert heat, park in the shade when possible, and give cans airflow. After dusty trails, clean grit from cap threads and sealing surfaces to maintain the vapor seal.

Rotation, stabilizers, and lifespan

Unstabilized pump gasoline ages quickly. For seasonal storage, add fuel stabilizer and rotate stock every few months. Use the oldest fuel first and mark dates on the can. Inspect seals and spouts for cracks or stiffness. Replace parts that no longer seal. If a can becomes swollen, cracked, or dented at a seam, retire it. Do not keep unknown old fuel. Recycle or dispose at a proper hazardous waste facility.

Spill readiness and cleanup

Even careful handling can lead to a spill. Keep absorbent pads, a small bag of oil dry, nitrile gloves, and a sealable waste bag with your fuel kit. Stop the spill, ventilate the area, and keep away from ignition sources. Do not hose fuel into soil or drains. Contain, absorb, and dispose through your community hazardous waste program. After a spill, wash the container exterior and the mount so odors do not linger.

Quick checklist for gas can storage

• Use only listed or certified containers with intact seals
• Label fuel type and date, leave expansion space, and keep caps tight
• Store in a ventilated area away from ignition and living spaces
• Mount outside the cabin when transporting and secure upright
• Carry a spill kit and rotate fuel to keep it fresh

How OZK Customs plans fuel storage into a build

When a van is designed for long travel or off grid routes, fuel reserves are part of trip planning. Integrating gas can storage into the vehicle is safer than improvising mounts after the fact. OZK Customs builds exterior carriers that lock cans upright, add airflow, and position weight where the chassis handles it best. For interior needs, we engineer ventilated compartments with sealed barriers, drain paths, and clearances from heat or electrical systems. Our fabrication team matches mounts to your platform and travel style so fuel is secure, quiet, and easy to access at the trailhead or station.

We work through your range goals and refuel locations, then size mounts and cabinets accordingly. That might mean a single can on a swing out for weekend trips or a more substantial solution for remote routes where stations are rare. The result is a rig that manages vapor, weight, and access without clutter. If your next build needs safe fuel storage, we will design it into the van from day one.

Your safety plan should include proper fuel storage. Let us design the mount, the ventilation, and the access points so you can focus on the drive.

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OZK Customs creates complete adventure vans and overland upfits that put safety and function first. From exterior carriers to clean interior compartments, every detail is planned and built for the miles ahead. Reach out and we will map your storage strategy into a van that fits how you travel.